Insertion Flow Meters

High accuracy, straightforward installation, and the flexibility to accommodate a wide range of flow rates.

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Whether striving to meet new requirements, improve process efficiency or reduce variability, an insertion flow meter provides a quick and cost-effective solution to the challenge of measuring industrial gas flows. Suitable for new systems or as a retrofit to upgrade or enhance the capability on existing equipment, its straightforward installation minimizes operational disruption.

Thermal mass technology minimizes pressure drops in the gas stream. Flow values are reported precisely and virtually instantaneously, regardless of fluctuations in flow rate. For reliable gas flow measurement, insertion flow meters have many advantages over alternative technologies.

  • High accuracy: Advances in thermal mass flow technology mean insertion flow meters like the QuadraTherm® 640i are accurate to +/- 0.75% of reading above 50% of full scale.

  • Wide turndown ratio: A ratio of 100:1 or better makes insertion mass flow meters from Sierra Instruments ideal for applications where flows vary widely and can also reduce spare holding requirements.

  • Easy to install: An insertion flow meter can be hot-tapped in the pipe or duct. There’s no need to cut out and replace sections. 

More About Insertion Flow Meters 

Accurate mass flow measurement is of increasing importance in many industries. Even when not required to maintain regulatory compliance, it provides data to support higher levels of process efficiency and reduced waste. When evaluating meter technology for an industrial application, know that insertion flow meters from Sierra Instruments: 

  • Provide a direct measurement of mass rather than volumetric flow, which is required in many process control situations
  • Are suitable for use with all widely used industrial and process gases
  • Factory calibration to your application ensures a quick and efficient startup.
  • Interface with widely used industrial communication protocols
  • Validate in the field for easy in-situ calibration (640/780 models)  
  • Patented zero drift DrySense™ velocity sensor (640i, 640S, 780i, and 780S models only)
  • Lifetime warranty on sensor (640i, 640S, 780i, and 780S models only) 
 

Additional Features 

Sierra Instruments maintains a network of technical support experts in over 150 countries around the globe. These experienced specialists are backed by  flow centers of excellence strategically located around the globe. 

  • Localized and Global Support: Reach specialists wherever you are and whenever you need them.

  • Commissioning: Sierra Instruments will give you ample help and assistance to get your flow meters operational in the least possible time.

  • Lifetime Support: Sierra Instruments stands behind every flow meter with calibration, repair, and replacement options for as long as required. 

Insertion Flow Meters FAQs

Q: How are the meters able to work with different types and compositions of gases?
A: Like solids, different gases have their own particular properties, and this results in different rates of thermal flow from the heated part of the sensor. To address this, each thermal mass insertion flow meter is calibrated to the composition of gas flowing through the pipe or duct.

Q: Are there any limitations on where an insertion flow meter can be installed in the piping?
A: There should be a straight run immediately upstream of the flow meter as this reduces turbulence in the flow. Ideally, the upstream straight run will be equivalent to at least 15 pipe diameters and as short as 1 pipe diameter downstream for qTherm depending on piping conditions.
 

Q: Does an insertion flow meter cause any pressure drop in the pipe?
A: Placing any solid object in the stream inevitably causes some perturbation of the flow. A Sierra Instruments insertion flow meter has a small enough probe that the reduction in cross-sectional area available for gas flow is basically zero and thus pressure drop is negligible. 

Insertion Flow Meter Resources 

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SteelMassTM 640S

Insertion Gas Mass Flow Meter

  • Insertion, totalizing air/gas mass flow meter
  • Eliminate drift with patented DrySense™ sensor
  • Increase flexibility with low pressure drop, high turndown
  • Validate in the field for easy in-situ calibration
  • Backed by lifetime sensor warranty
FastFlo 620S

Fast-Response Insertion Thermal Mass Air Flow Sensor

  • Increase efficiency with fast response time within 200 milliseconds
  • Optimized air, nitrogen, and inert gas measurement for 1, 2, 3, 4 inch sch. 40 pipe sizes
  • Wide flow ranges from 0 to 42,000 scfh
  • Easily install in the field or retrofit
BoilerTrak 620S-BT

Insertion Thermal Mass Flow Meter for Boiler & Heater Efficiency

  • Optimized natural and propane measurement for 1, 2, 3, 4 inch sch. 40 pipe sizes
  • Wide flow ranges from 0 to 42,000 scfh
  • Easily install in the field or retrofit
  • Certified for GHG measurement meeting EPA (40 CFR Part 98)
  • Boiler MACT certified for area source boilers (40 CFR 63, subpart JJJJJJ) and for major source boilers (40 CFR 63, subpart DDDDD) Learn More
QuadraTherm® 640i

Industry's Most Accurate Air / Gas Thermal Insertion Mass Flow Meters

  • Achieve high accuracy +/- 0.75% of reading
  • Eliminate drift with patented DrySense™ sensor
  • Validate in the field for easy in-situ calibration
  • Use qMix software to easily change gas composition in the field and retain accuracy Download Flare Gas Mass Measuring Tech Note
  • Backed by lifetime sensor warranty
  • Boiler MACT certified for area source boilers (40 CFR 63, subpart JJJJJJ) and for major source boilers (40 CFR 63, subpart DDDDD) Learn more > 
  • Part of Sierra's Big-3 iSeries family of flow meter technologies Learn more >
  • Meet EPA rule 40 CFR 63 for flare gas measurement at ultra-low flows down sfps (0.03 smps) with QuadraTherm® qMix RealTime Flare Measurement System (FMS)
BioTrakTM 645S/745S

Wastewater Thermal Mass Flow Meter

  • Direct mass flow measurement maintains precise control of aeration, digestion, and cogeneration
  • Microprocessor based, field-programmable electronics
  • Wide measurement range up to 1000:1 turndown; 100:1 typical
  • DigiSense sensor design / Swivel probe ±180° into four positions
  • BioSelect™ menu provides field selectable air, methane, and digester gas
  • BioView™ software provides access to meter data / Configure meter settings in field
  • BioCal™ verifies calibration within five minutes
BioTrak™ 645i/745i 

Wastewater Dedicated Thermal Mass Flow Meter

  • Field-Selectable Gases-air, methane, digester gas 
  • Direct mass flow measurement maintains precise control of aeration, digestion, and cogeneration 
  • Accuracy: Air: +/-1% of reading +/-0.2% of full scale  - Other gases: +/-1.5% of reading +/-0.5% full scale 
  • Insertion and inline versions
  • AC or DC power input available 
  • Optional hot top packing gland and retractor 
  • Integral and remote electronic configurations available 
  • Wide measurement range up to 1000:1 turndown; 100:1 typical 
  • BioCal Calibration Validation within five minutes  
TM100™

Economical Industrial Thermal Mass Flow Meters

  • Accuracy 
    • +/- 1.0% of reading plus +/- 0.2% of full-scale – Air, Nitrogen 
    • +/- 1.5% of reading plus +/- 0.5% of full-scale – All other gases
  • Repeatability +/- 0.2% of full scale
  • Direct measurement of gas mass flow / No volume to mass calculations
  • DigiSense™ robust sensor design
  • 12 to 24 volt DC power 
  • Use optional Gas-Mix™ feature to easily change gas selection or create gas mixes in the field - no recal required  
  • 2–3-week delivery lead times / 1-week delivery possible
TM500™

High Performance Industrial Thermal Mass Flow Meter

  • Accuracy 
    • +/- 1.0% of reading plus +/- 0.2% of full-scale – Air, Nitrogen 
    • +/- 1.5% of reading plus +/- 0.5% of full-scale – All other gases
  • Repeatability +/- 0.2% of full scale
  • Direct measurement of gas mass flow / No volume to mass calculations
  • DigiSense™ robust sensor design
  • AC or DC power 
  • Use optional Gas-Mix™ feature to easily change gas selection or create gas mixes in the field - no recal required 
  • 2-3 week delivery lead times / 1 week delivery possible

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